D-814, D-824 Centrifugal Pumps User Instructions: Installation, Operation, Maintenance (PCN=75373613 05/04)

D-814, D-824 Centrifugal Pumps User Instructions: Installation, Operation, Maintenance (PCN=75373613 05/04)
®
Pump Division
D-814, D-824 Centrifugal Pumps
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN=75373613 – 05/04
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
CONTENTS
1.
INTRODUCTION AND SAFETY ..................3
1.1 General ................................................3
1.2 CE marking and approvals ....................3
1.3 Disclaimer ............................................3
1.4 Copyright..............................................3
1.5 Duty conditions .....................................4
1.6 Safety ..................................................4
1.7 Warning labels......................................6
1.8 Noise level............................................7
2.
TRANSPORT AND STORAGE ....................8
2.1 Consignment receipt and unpacking .....8
2.2 Handling.............................................8
2.3 Lifting .................................................8
2.4 Storage...............................................9
2.5 Recycling and end of product life..........9
3.
DESCRIPTION ...........................................10
3.1 Configurations .....................................10
3.2 Nomenclature......................................10
3.3 Design of major parts...........................10
3.4 Performance and operation limits .........10
4.
INSTALLATION..........................................15
4.1 Cleaning prior to installation.................15
4.2 Location..............................................15
4.3 Part assemblies...................................15
4.4 Foundation..........................................15
4.5 Grouting..............................................16
4.6 Initial alignment ...................................17
4.7 Piping ................................................18
4.8 Electronic connections .........................20
4.9 Final shaft alignment check..................20
5.
COMMISSIONING, STARTUP,
OPERATION AND SHUTDOWN..................21
5.1 Pre-commissioning procedure ..............21
5.2 Direction of rotation .............................21
5.3 Guarding.............................................21
5.4 Priming and auxiliary supplies ..............21
5.5 Starting the pump ................................22
5.6 Running or operation...........................22
5.7 Stopping and shutdown........................23
5.8 Hydraulic, mechanical and
electrical duty......................................23
4
6.
MAINTENANCE ......................................... 24
6.1 Maintenance schedule ....................... 24
6.2 Spare parts ....................................... 25
6.3 Recommended spares and
consumable items.............................. 25
6.4 Fastener torques ............................... 25
6.5 Disassembly procedure...................... 26
6.6 Examination and repair of parts .......... 26
6.7 Assembly of pump and seal................ 27
7.
FAULTS: CAUSES AND REMEDIES........... 29
8.
PARTS LIST AND DRAWINGS ................... 31
8.1 Model D-814 (flanged) ....................... 31
8.2 Model D-814 (threaded)..................... 32
8.3 Model D-824 (flanged) ....................... 33
8.4 Model D-824 (threaded)..................... 34
8.5 Exploded parts diagram ..................... 35
9.
CERTIFICATION ........................................ 36
10. OTHER RELEVANT
DOCUMENTATION AND MANUALS ........... 36
10.1 Supplementary user instructions ......... 36
10.2 Change notes .................................... 36
10.3 Additional sources of information........ 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
1 INTRODUCTION AND SAFETY
1.2 CE marking and approvals
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve's products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilizing sophisticated quality techniques, and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at your service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not take
into account local regulations; ensure such regulations
are observed by all, including those installing the
product. Always coordinate repair activity with
operations personnel, and follow all plant safety
requirements and applicable safety and health laws/
regulations.
These instructions should be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met.
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
incorporates information relevant to these Directives
and Approvals. To confirm the Approvals applying
and if the product is CE marked, check the serial
number plate markings and the Certification, see
section 9, Certification.
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Pump Division to provide sound and
all necessary information the content of this
manual may appear insufficient and is not
guaranteed by Flowserve as to its completeness
or accuracy.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organizations. Genuine parts and
accessories have been designed, tested and
incorporated into the products to help ensure
continued product quality and performance in use.
As Flowserve cannot test parts and accessories
sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features
of the products. The failure to properly select, install
or use authorized Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered by Flowserve's warranty. In
addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
Page 3 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user
seeks Flowserve’s written agreement before start up.
1.6 Safety
1.6.1
Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction
would cause hazards. The specific safety markings
are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and
could result in loss of life.
This symbol indicates “hazardous and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This sign is not a safety symbol but
indicates an important instruction in the assembly
process.
1.6.2
Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3
Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
(Lock Out)
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUOROELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of
fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb.) use a crane
appropriate for the mass and in accordance with
current local regulations.
NEVER OPERATE THE PUMP WITHOUT THE
COUPLING GUARD AND ALL OTHER SAFETY
DEVICES CORRECTLY INSTALLED
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
Page 4 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
NEVER OPERATE THE PUMP WITH
THE DISCHARGE VALVE CLOSED
(Unless otherwise instructed at a specific point in the
user instructions.)
(See section 5, Commissioning start-up, operation
and shutdown.)
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapor could cause an explosion.
NEVER RUN THE PUMP DRY OR
WITHOUT PROPER PRIME (Casing Flooded)
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
equipment can present a danger to operators and
persons entering the immediate area, action must be
taken to avoid accidental contact (such as shielding).
If complete protection is not possible, the machine
access must be limited to maintenance staff only with
clear visual warnings and indicators to those entering
the immediate area. Note: bearing housings must not
be insulated and drive motors and bearings may be
hot.
If the temperature is greater than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation
and shutdown.)
NEVER OPERATE THE PUMP WITH
THE SUCTION VALVE CLOSED
It should be fully opened when the pump is running.
NEVER OPERATE THE PUMP AT
ZERO FLOW OR FOR EXTENEDED PERIODS
BELOW THE MINIMUM CONTINUOUS FLOW
THE PUMP SHAFT MUST TURN
CLOCKWISE WHEN VIEWED FROM THE MOTOR
END
It is absolutely essential that the rotation of the motor
be checked before starting the pump.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate pump placement, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
NEVER EXCEED THE MAXIMUM
DESIGN PRESSURE (MDP) AT THE
TEMPERATURE SHOWN IN 3.4.4
See section 3 for pressure versus temperature
ratings based on the material of construction.
Page 5 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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1.7 Warning labels
Alignment warning:
Coupling guard warning:
WARNING.
BEFORE GROUTING RE-ALIGN THIS UNIT.
RECHECK ALIGNMENT BEFORE STARTING.
FAILURE TO RE-ALIGN THIS UNIT MAY RESULT
IN SERIOUS OPERATING DIFFICULTIES, BEARING
FAILURE, OR OTHER UNNECESSARY DAMAGE.
FOR METHOD OF CHECKING ALIGNMENT SEE
INSTRUCTIONS ATTACHED TO COUPLING OR
REFER TO INSTALLATION INSTRUCTION IN
INSTRUCTION BOOK.
Page 6 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
1.8 Noise level
Bare Pump Noise Level
Pump Size
When pump noise level exceeds 85dBA attention
must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to
control exposure time to the noise or to enclose the
machine to reduce emitted sound. You may have
already specified a limiting noise level when the
equipment was ordered, however if no noise
requirements were defined then machines above a
certain power level will exceed 85dBA. In such
situations consideration must be given to the fitting of
an acoustic enclosure to meet local regulations.
2 1/2x2 1/2x4T
3x3x4F
2 1/2x1 1/2x5T
3x1 1/2x5F
3x2x5F
3x2x5T
4x3x5F
1 1/2x1x6T
1 1/2x1x6F
2x1x6T
2 1/2x1 1/2x6T
3x1 1/2x6F
3x2x6F
3x2x6T
4x3x6F
6x4x6F
1 1/2x1x8F
2x1x8T
2 1/2x1 1/2x8T
3x1 1/2x8F
3x2x8F
3x2x8T
4x3x8F
6x4x8F
2x1 1/2x9F
3x2x9F
4x3x9f
2x1x10F
3x1 1/2x10F
3x2x10F
4x3x10F
6x4x10F
6x4x11F
5x4x12F
6x5x12F
3x1 1/2x13F
3x2x13F
4x3x13F
6x4x13F
5x4x15F
6x4x15F
Pump noise level is dependent on a number of
factors - the type of driver, the operating capacity,
piping design and acoustic characteristics of the
building.
If a pump unit only has been purchased, for fitting
with your own driver, then the "bare pump" noise
levels from the table should be combined with the
level for the driver obtained from the supplier. If the
motor is driven by an inverter, it may show an
increase in noise level at some speeds. Consult a
Noise Specialist for the combined calculation.
1.8.1 D-814 bare pump noise level information
Below is a tabulation of sound pressure readings for
frame mounted D-814 pumps for general information
and not to be subject to guarantee by Flowserve.
Tests were conducted in accordance with the
th
Standards of the Hydraulic Institute, 13 Edition,
1975. Pumps were tested in a spacious room
(simulating an open field) with driver covered by a
sound absorbing enclosure and with system valves,
venturi’s, and tanks behind a sound absorbing wall.
Decibel readings do not include driver or system
noise. Pumps were tested through a normal operating
range of about 75% to 125% of the best efficiency
point at all impeller diameters.
dBA @3550 dBA @ 1770
RPM
RPM
70
70
70
60
70
60
70
60
70
60
70
60
70
60
70
60
70
60
70
60
70
60
72
60
72
60
75
60
80
62
75
60
75
60
75
60
75
60
75
60
75
60
77
62
79
64
80
70
80
70
80
70
77
67
79
70
80
70
81
70
70
72
75
75
70
70
72
75
80
80
9-inch, 12-inch, and 15-inch pumps have not
been tested. These figures should be used as
estimates only.
Page 7 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no
damage in transportation. Any shortage and/or
damage must be reported immediately to Flowserve
Pump Division and must be received in writing within
one month of receipt of the equipment. Later claims
cannot be accepted.
A crane must be used for all pump sets in
excess of 25 kg (55 lb.). Fully trained personnel
must carry out lifting in accordance with local
regulations.
FIGURE 2-1
Check all crates, boxes or wrappings for any
accessories or spare parts that may be packed
separately from the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
quote this number in correspondence as well as
when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork-lift vehicles or slings depending on their
size and construction.
2.3 Lifting
Pumps and motors often have
integral lifting lugs or eye bolts. These are intended
for use in only lifting the individual piece of
equipment.
Do not use eye bolts or cast-in lifting
lugs to lift pump, motor and baseplate assemblies.
To avoid distortion, the pump unit
should be lifted as shown.
Care must be taken to lift
components or assemblies above the center of
gravity to prevent the unit from flipping.
Lifting bare pump
Horizontal Pumps: Sling around the pump discharge
nozzle and around the outboard end of the bearing
housing with separate slings. Choker hitches must
be used at both attachment points and pulled tight.
Make sure the completion of the choker hitch on the
discharge nozzle is toward the coupling end of the
pump shaft as shown in Figure 2-1. The sling
lengths should be adjusted to balance the load
before attaching the lifting hook.
Lifting pump, motor and baseplate assembly
Horizontal: If the baseplate has lifting holes cut in
the sides at the end, insert lifting S hooks at the four
corners and use slings or chains to connect to the
lifting eye as shown in Figure 2-1. Do not use slings
through the lifting holes.
For other baseplates, sling around the pump
discharge nozzle, and around the outboard end of
the motor frame using choker hitches pulled tight
(Figure 2-1).
The sling should be positioned so the weight is not
carried through the motor fan housing. Make sure
the completion of the choker hitch on the discharge
nozzle is toward the coupling end of the pump shaft
as shown in Figure 2-1.
Page 8 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
2.4 Storage
2.5 Recycling and end of product life
Store the pump in a clean, dry
location away from vibration. Leave flange covers in
place to keep dirt and other foreign material out of
pump casing. Turn the pump shaft at regular
intervals to prevent brinelling of the bearings and the
seal faces, from sticking.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
Short term storage
Normal packaging is designed to protect the pump
and parts during shipment and for dry, indoor
storage for up to six months or less.
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and in accordance with local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with current
local regulations. This also includes the liquids
and/or gases that may be used in the "seal system"
or other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the
current regulations at all times.
Normal packaging:
a) All loose unmounted items are packaged in a
water proof plastic bag and placed under the
coupling guard. Larger items are boxed and
banded to the baseplate. For pumps not
mounted on a baseplate, the bag and/or box is
placed inside the shipping container.
b) Flange covers are secured to both the suction
and discharge flanges.
c) Assemblies ordered with external piping, in
some cases components may be disassembled
for shipment.
Page 9 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
3 DESCRIPTION
j)
3.1 Configurations
The D-814 Pump is a frame mounted volute type
centrifugal pump designed to be coupled to a
separate driver such as an induction motor. The D824 Monobloc is the same type of pump but close
coupled to a NEMA-Hydraulic Institute Standard Type
JM Pump Motor. The shaft extension and mounting
flange of the D-814 frame are identical to those of the
same size JM motor shaft extension and mounting
flange. The type of pump is of a standardized design
with a minimum number of optional components.
Design features are hydraulically balanced closed
impeller and single mechanical seal. The D-814
utilizes standard sealed for life bearings. Available
materials of construction are shown in section 3.4.5.
FIGURE3-1 Nameplate
a
d
®
c
f
g
i
k
3.3 Design of major parts
3.3.1 Pump casing
Removal of the casing is not required when
performing maintenance of the rotating assembly.
The pump is designed with a gasket perpendicular to
the shaft allowing the rotating assembly to be easily
removed (back pull out).
3.3.3 Shaft / Sleeve
Sleeved shafts are supported on bearings, with keyed
impeller and shaft coupling.
Memphis,Tenneessee
SERIAL
NO.
SIZE
TYPE
GPM
*Only used if specified on factory job bill of
material.
3.3.2 Impeller
The impeller is the closed type.
3.2 Nomenclature
b
“PUMP MAT’L” Major construction materials of
the pump.
k) “REF. NO.” Customer reference/item number.
l) “RPM” Motor RPM data.*
e
TDH(FT)
MAX. DESIGN AT
AMB. TEMP (PSIG)
IMP. DIA.
INSTLLD(IN)
LUBE
REF.
NO.
SP.
GR.
MAX. IMP.
DIA.(IN)
PUMP
MAN’T
RPM
h
j
l
DO NOT OPERATE WITHOUT FIRST READING INSTRUCTION BOOK
PARTS INFORMATION
3.3.4 Pump bearing lubrication
Permanently lubricated ball bearings are fitted as
standard.
3.3.5 Cover
The cover has a spigot (rabbet) fit between the pump
casing and bearing housing (cover) for optimum
concentricity.
3.3.6 Shaft seal
The mechanical seal, attached to the pump shaft,
seals the pumped liquid from the environment.
Details of nameplate
a) “SERIAL NO.” This number corresponds to
records that will enable your Flowserve Pump
Division representative to determine the
component parts of your pump so exact duplicate
parts or specific technical assistance can be
provided.
b) ”SIZE TYPE” Suction pipe size X discharge pipe
size X impeller. (not exact imp. dia.)
c) “GPM” Gallons per minute.*
d) “TDH(FT)” Total Head (FT).*
e) “SP. GR.” Specific gravity of liquid being
pumped.*
f) “MAX DESIGN AT AMB. TEMP (PSIG)”
Maximum allowable design pressure.
g) “IMP. DIA INSTLLD(IN)” Diameter in inches, of
installed impeller.
h) ”MAX. IMP. DIA(IN)” Maximum available impeller
diameter in inches.
i) “LUBE” Not applicable- sealed for life bearings.
3.3.7 Driver
The driver is normally an electric motor. Different
drive configurations may be fitted such as internal
combustion engines, turbines, hydraulic motors etc
driving via couplings, belts, gearboxes, drive shafts
etc.
3.3.8 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operation limits
The following data is included as additional
information to help with installation. Factors such as
liquid being pumped, temperature, material of
construction, and seal type may influence this data.
Page 10 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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3.4.1 D-800 design information
Pump Size
Suction
Size
(in.)
Discharge
Size
(in.)
Maximum
Working
Pressure (psig)
Hydrotest
Pressure
(psig)
2 1/2x2 1/2x4T
3x3x4F
2 1/2x1 1/2x5T
3x1 1/2x5F
3x2x5F
3x2x5T
4x3x5F
1 1/2x1x6T
1 1/2x1x6F
2x1x6T
2 1/2x1 1/2x6T
3x1 1/2x6F
3x2x6F
3x2x6T
4x3x6F
6x4x6F
1 1/2x1x8F
2x1x8T
2 1/2x 1 1/2x8T
3x1 1/2x8F
3x2x8F
3x2x8T
4x3x8F
6x4x8F
2 1/2x1 1/2x9F
3x2x9F
4x3x9F
2x1x10F
3x1 1/2x10F
3x2x10F
4x3x10F
6x4x10F
6x4x11F
5x4x12F
6x5x12F
3x1 1/2x13F
3x2x13F
4x3x13F
6x4x13F
5x4x15F
6x5x15F
2 1/2
3
2 1/2
3
3
3
4
1
1
2
2 1/2
3
3
3
4
6
1 1/2
2
2 1/2
3
3
3
4
6
2
3
4
2
3
3
4
6
6
5
6
3
3
4
6
5
6
2 1/2
3
1 1/2
1 1/2
2
2
3
1
1
1
1 1/2
1 1/2
2
2
3
4
1
1
1 1/2
1 1/2
2
2
3
4
1 1/2
2
3
1
1 1/2
2
3
4
4
4
5
1 1/2
2
3
4
4
5
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
200
200
200
220
220
220
220
175
175
125
125
175
175
175
175
150
150
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
265
300
300
300
330
330
330
330
265
265
185
185
265
265
265
265
225
225
Page 11 of 36
Minimum
Casing
Thickness
(in.)
0.25
0.25
0.25
0.25
0.25
0.25
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.35
0.35
0.28
0.30
0.30
0.30
0.30
0.30
0.35
0.38
0.44
0.44
0.47
0.35
0.35
0.35
0.35
0.47
0.51
0.50
0.53
0.55
0.55
0.55
0.51
0.56
0.63
Casing /
Impeller Hub
Clearance (in.)
0.012-0.017
0.018-0.022
0.012-0.017
0.018-0.024
0.012-0.017
0.012-0.017
0.021-0.025
0.010-0.015
0.018-0.024
0.010-0.015
0.012-0.017
0.018-0.024
0.018-0.024
0.012-0.017
0.021-0.027
0.021-0.027
0.018-0.024
0.010-0.015
0.012-0.017
0.018-0.024
0.018-0.024
0.012-0.017
0.021-0.027
0.021-0.027
0.010-0.017
0.010-0.017
0.010-0.017
0.012-0.017
0.012-0.017
0.010-0.017
0.021-0.027
0.021-0.027
0.021-0.027
0.010-0.017
0.010-0.017
0.018-0.024
0.018-0.024
0.021-0.027
0.028-0.032
0.010-0.017
0.010-0.017
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
3.4.2 Temperature limitations
The maximum temperature of the liquid that can be
pumped by a D-800 is dependent on the
conduction of the heat along the pump / motor shaft
to the bearings, design, and materials of the
mechanical seal on the pump, and the
characteristics of the fluid being pumped as it
relates to the materials of construction.
Temperature Limitations
Pump Type
Pump
Fittings
D814 Frame Mounted
All
D824 Close Coupled
All
3.4.3 Maximum suction pressure limitations
Maximum Suction Pressure – 75 psig
The sum of suction pressure and
maximum head developed by the pump at shutoff
should remain below the maximum allowable
working pressure of the pump at rated temperature.
Refer to section 3.4.4, Maximum working pressure
limitations, for maximum allowable working
pressure.
Page 12 of 36
o
Temperature Limit - F
Maximum
Minimum
225
-20
250
-20
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
Maximum case working pressure -- psig
3.4.4 Maximum working pressure limitations
The maximum working pressure of a pump is
determined by the physical strength of the casing
and cover materials, material thickness, bolting and
gaskets. The D-800 iron casing material is the
primary factor limiting working pressure. Working
pressure also varies with pumping temperature.
The chart below indicates this variation.
10” Pumps (except 6x4x10)
220
200
180
160
140
120
100
80
60
40
20
0
Dotted line for hot oils
and non-water
containing liquids
9” Pumps
4,5,6,8,11 & 6x4x10 Pumps
15” Pumps
Limits for liquids
containing water
12” Pumps
Protect pump from freezing
-50
0
50
100 150 200 250 300 350
Temperature -- oF
-50
0
50
100
o
Temperature -- C
Final selection must be made based
on mechanical seal limits given in General Data
Section.
Page 13 of 36
150
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
3.4.5 Standard materials of construction
Standard Fitted
All Iron Fitted
Part
D-814
D-824
D-814
D-824
1
Casing
ASTM A278 Class 25 Cast Iron
Casing Wear Ring
Casing Gasket
Impeller
2
Bronze (optional)
Steel (bar)
3
(optional)
Syntheic Fibers with Nitrile Binder
C90300, C90500, C90700
Cast Iron 25
Bronze
ASTM A351 SS
Grade CF8M
Cast SS
ASTM A278 Class 25 Cast Iron
ASTM A351 SS
Grade CF8M
Cast SS
Bronze
Cast Iron
316 SS
Bronze
416 SS
Carbon Steel
Carbon Steel
Carbon Steel
316 SS
Syntheic Fibers with Nitrile Binder
Cover
Cover Ring
Sleeve
Bolts
Shaft
Key
Impeller Washer
Impeller Washer
Gasket
Impeller Screw
4
Pump Bracket
Bearing Frame
Support Foot
Mechanical Seal
(Type 21)
Inducer (optional)
316 Stainless Steel
D-814
D-824
ASTM A351 SS Grade
CF8M Cast SS
------
Ductile Iron
Cast Iron
Steel
304 SS
N/A
Ductile Iron N/A Ductile Iron
N/A
Cast Iron
N/A
Cast Iron
N/A
Steel
N/A
Steel
Faces: Carbon vs. Ceramic
Buna-N Bellows 18-8SS Metal Parts
316 SS
N/A
N/A
N/A
Footnotes apply to these sizes only: 2 1/2x1 1/2x9, 3x2x9, 5x4x12, 6x5x12, 5x4x15, 6x5x15.
Casing Iron – 30.
2
Bronze wear ring supplied as standard.
3
Iron wear ring supplied as standard.
4
Casing foot is an integral part of casing.
1
Page 14 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
4 INSTALLATION
4.1 Cleaning prior to installation
that occurred during handling. Normal industry
practice is to achieve final alignment by moving
the motor to match the pump. Flowserve’s
practice is to confirm in our shop that the pump
assembly can be accurately aligned. Before
shipment, the factory verifies that there is
enough horizontal movement capability at the
motor to obtain a “perfect” final alignment when
the installer puts the baseplate assembly into its
original, top leveled, unstressed condition.
Clean suction and discharge flange surfaces or
pipe connections. If any debris has entered the
motor through fan or cooling openings, remove it.
4.2 Location
The pump should be located to allow room for
access, ventilation, maintenance, and inspection
with ample headroom for lifting, and should be as
close as practical to the supply of liquid to be
pumped.
4.3 Part assemblies
The supply of motors and baseplates are optional.
As a result, it is the responsibility of the installer to
ensure that the motor is assembled to the pump
and aligned as detailed in section 4.6 and 4.9.
4.4 Foundation
4.4.1 Rigid baseplates - overview
The function of a baseplate is to provide a rigid
foundation under a pump and its driver that
maintains alignment between the two.
Baseplates intended for grouted installation are
designed to use the grout as a stiffening member.
Regardless of the type of baseplate used, it must
provide three functions to ensure a reliable
installation.
a) The baseplate must provide sufficient rigidity to
assure the assembly can be transported and
installed, given reasonable care in handling,
without damage. It must also be rigid enough
when properly installed to resist operating loads.
b) The baseplate must provide a reasonably flat
mounting surface for the pump and driver.
Uneven surfaces will result in a soft-foot
condition that may make alignment difficult or
impossible. Flowserve’s experience indicates
that a baseplate that has a top surface flatness
1
of ±1.6 mm (± /16 in.) across the diagonal
corners of the baseplate provides such a
mounting surface. Therefore, this is the
tolerance to which we supply our standard
baseplate.
c) The baseplate must be designed to allow the
user to final field align the pump and driver to
within their own particular standards and to
compensate for any pump or driver movement
4.4.2 Foundation D-814
Flowserve recommends mounting D-814 pumps on
permanent foundations to prevent excessive strains
from piping connections and coupling
misalignment. Figure 4-1 shows a typical
installation.
Ideally pumps should be installed in a horozontal
position using steel baseplates on a permanent
masonry or structural steel foundation of sufficient
mass to absorb all normal vibrations. Foundation
bolts should be located or embedded in the
concrete by layout or template in relation to the
suction and discharge piping. If concrete is used,
foundation bolts of the specified size may be
enclosed in a pipe sleeve two or three diameters
larger than the bolts to compensate for minor
vibration in lineup.
Channel steel bases are bolted in place. Drain rim
steel bases may be grouted if desired.
Accessory steel baseplates furnished with these
pumps and motors 10 hp and under may be bolted
to machine or equipment structures, either rigidly
or, if flexible piping is used, with properly designed
vibration isolators.
Small units (10 hp and under) may be operated in
tempory installations without permanent foundation
attachments if mounted on standard channel steel
or drain rim steel baseplates under the following
conditions.
a) Use flexible piping connections such as hose
which will not impose heavy pipe strains on
pump casing but will not rupture or leak if unit
shifts slightly due to vibration or external forces.
b) Connect motor with safe durable electrical
connections which will not be affected by slight
shifting of the unit.
c) Conditions of coupling misalignment may
shorten life of motor and pump bearings.
Page 15 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
FIGURE 4-1 Typical Installation
4.4.3 Foundation D-824
The main purpose of the mounting for the
Monobloc pump is to prevent any shifting which
could result in the pump weight being supported by
the connection piping. If this happens, internal
damage to pump parts could occur. If flexible piping
or hose is used, the mounting need only support
the weight of the pump and any vibrations that
might occur. Monobloc pumps are normally
mounted horizontally. However, they may be
mounted vertically or in other positions. If the liquid
end is above motor, any leakage from the pump
may enter and damage the motor bearings.
Monobloc pumps should be fastened to their
foundations by using four of the mounting bolt
holes in the motor feet. Do not depend upon piping
to hold the pump in place even with the smallest
units. Bolt pumps above 15 hp to masonry or
structural steel foundations. Smaller units may be
bolted to machine or equipment structures either
rigidly or, flexible piping is used, with properly
designed vibration isolators. Units with large
casings and small motors require a builtup
mounting under the motor feet. On some large
units, an auxiliary foot is provided under the casing.
The feet must match mounting surfaces exactly or
it will be necessary to shim. Tighten the motor
mounting bolts after the piping connections are
securely attached to the pump.
4.5 Grouting
This section applies only to drip rim of
formed steel baseplates with grout holes.
a)
Page 16 of 36
The pump foundation should be located as
close to the source of the fluid to be pumped
as practical. There should be adequate space
for workers to install, operate and maintain the
pump. The foundation should be sufficient to
absorb any vibration and should provide a
rigid support for the pump and motor.
Recommended mass of a concrete foundation
should be three times that of the pump, motor
and base. Refer to Figure 4-2. Note that
foundation bolts are imbedded in the concrete
inside a sleeve to allow some movement of the
bolt.
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
FIGURE 4-2
b)
c)
d)
Level the pump baseplate assembly. If the
baseplate has machined coplanar mounting
surfaces, these machined surfaces are to be
referenced when leveling the baseplate. This
may require that the pump and motor be
removed from the baseplate in order to
reference the machined faces. If the
baseplate is without machined coplanar
mounting surfaces, the pump and motor are to
be left on the baseplate. The proper surfaces
to reference when leveling the pump baseplate
assembly are the pump suction and discharge
flanges. DO NOT stress the baseplate. Do
not bolt the suction or discharge flanges of the
pump to the piping until the baseplate
foundation is completely installed. If equipped,
use leveling jackscrews to level the baseplate.
If jackscrews are not provided, shims or
wedges should be used (see Figure 4-2).
Check for levelness in both the longitudinal
and lateral directions. Shims should be placed
at all base anchor bolt locations, and in the
middle edge of the base if the base is more
than 1.5 m (5 ft) long. Do not rely on the
bottom of the baseplate to be flat. Standard
baseplate bottoms are not machined, and it is
not likely that the field mounting surface is flat.
After leveling the baseplate, tighten the anchor
bolts. If shims were used, make sure that the
baseplate was shimmed near each anchor bolt
before tightening. Failure to do this may result
in a twist of the baseplate, which could make it
impossible to obtain final alignment. Check
the level of the baseplate to make sure that
tightening the anchor bolts did not disturb the
level of the baseplate. If the anchor bolts did
change the level, adjust the jackscrews or
shims as needed to level the baseplate.
Continue adjusting the jackscrews or shims
and tightening the anchor bolts until the
baseplate is level.
Check initial alignment. Pumps are given a
preliminary alignment at the factory. This
preliminary alignment is done in a way that
e)
f)
ensures that, if the installer duplicates the
factory conditions, there will be sufficient
clearance between the motor hold down bolts
and motor foot holes to move the motor into
final alignment. If the pump and motor were
properly reinstalled to the baseplate or if they
were not removed from the baseplate and
there has been no transit damage, and also if
the above steps where done properly, the
pump and driver should be within 0.38 mm
(0.015 in.) FIM (Full Indicator Movement)
parallel, and 0.0025 mm/mm (0.0025 in./in.)
FIM angular. If this is not the case, first check
to see if the driver mounting fasteners are
centered in the driver feet holes. If not, recenter the fasteners and perform a preliminary
alignment to the above tolerances by
shimming under the motor for vertical
alignment, and by moving the motor for
horizontal alignment.
Grout the baseplate. A non-shrinking grout
should be used. Make sure that the grout fills
the area under the baseplate. After the grout
has cured, check for voids and repair them.
Jackscrews, shims and wedges should be
removed from under the baseplate at this time.
If they were to be left in place, they could rust,
swell, and cause distortion in the baseplate.
Run piping to the suction and discharge of the
pump. There should be no piping loads
transmitted to the pump after connection is
made. Recheck the alignment to verify that
there are no significant loads.
4.6 Initial alignment
Mounting and alignment
Pumps operate most reliably when carefully aligned
on permanent rigid foundations. Strains which will
cause wear of internal parts of the pump and
excessive noise and vibration are eliminated this
way.
Pump-driver combinations are aligned at the
factory but must be rechecked for coupling
alignment because they may be sprung in shipment
or distorted by tightening of foundation bolts.
The best procedure to follow is to remove the
coupling guard and check coupling alignment
before tightening any foundation bolts.
If the pump is mounted on a permanent foundation,
tighten the bolts now and recheck coupling
alignment. Also turn the shaft by hand to assure
that it turns freely.
Page 17 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
If unit is to be grouted do it now. After the grout has
been poured and allowed to set for 48 hours tighten
foundation bolts evenly and securely. Recheck
coupling alignment. Replace coupling guard.
i)
Pumps on hot survice should have final coupling
alignment made with the unit at its operating
temperature.
j)
4.6.1 Factory alignment procedure.
The purpose of factory alignment is to ensure that
the user will have full utilization of the clearance in
the motor holes for final job-site alignment. To
achieve this, the factory alignment procedure
specifies that the pump be aligned in the horizontal
plane to the motor, with the motor foot bolts
centered in the motor holes. This procedure
ensures that there is sufficient clearance in the
motor holes for the customer to field align the motor
to the pump, to zero tolerance. This philosophy
requires that the customer be able to place the
base in the same condition as the factory. Thus
the factory alignment will be done with the base
sitting in an unrestrained condition on a flat and
level surface. This standard also emphasizes the
need to ensure the shaft spacing is adequate to
accept the specified coupling spacer.
The factory alignment procedure is summarized
below:
a)
b)
c)
d)
e)
f)
g)
h)
The baseplate is placed on a flat and level
workbench in a free and unstressed position.
The baseplate is leveled as necessary.
Leveling is accomplished by placing shims
under the rails of the base at the appropriate
anchor bolt hole locations. Levelness is
checked in both the longitudinal and lateral
directions.
The motor and appropriate motor mounting
hardware is placed on the baseplate and the
motor is checked for any planar soft-foot
condition. If any is present it is eliminated by
shimming
The motor feet holes are centered on the
motor mounting fasteners.
The motor is fastened in place by tightening
the nuts on two diagonal motor mounting
studs.
The pump is put onto the baseplate and
leveled. The foot piece under the bearing
housing is adjustable. It is used to level the
pump, if necessary.
The spacer coupling gap is verified.
The parallel and angular vertical alignment is
made by shimming under the motor.
k)
The motor feet holes are again centered on
the motor mounting studs using the centering
nut. At this point the centering nut is removed
and replaced with a standard nut. This gives
maximum potential mobility for the motor to be
horizontally moved during final, field
alignment. All four motor feet are tightened
down.
The pump and motor shafts are then aligned
horizontally, both parallel and angular, by
moving the pump to the fixed motor. The
pump feet are tightened down.
Both horizontal and vertical alignment is again
final checked as is the coupling spacer gap.
See section 4.9 for Final shaft alignment
4.7 Piping
The protective covers fitted to both
the suction and discharge of the casing must be
removed prior to connecting the pump to any pipes.
Isolation valves on suction and discharge lines are
recommended to facilitate future inspection and
repairs.
4.7.1 Suction and discharge piping
All piping must be independently supported,
accurately aligned and preferably connected to the
pump by a short length of flexible piping. The
pump should not have to support the weight of the
pipe or compensate for misalignment. It should be
possible to install suction and discharge bolts
through mating flanges without pulling or prying
either of the flanges. All piping must be tight.
Pumps may air-bind if air is allowed to leak into the
piping. If the pump flange(s) have tapped holes,
select flange fasteners with thread engagement at
least equal to the fastener diameter but that do not
bottom out in the tapped holes before the joint is
tight.
4.7.2 Suction piping
To avoid NPSH and suction problems, suction
piping must be at least as large as the pump
suction connection. Never use pipe or fittings on
the suction that are smaller in diameter than the
pump suction size.
Figure 4-3 illustrates the ideal piping configuration
with a minimum of 10 pipe diameters between the
source and the pump suction. In most cases,
horizontal reducers should be eccentric and
mounted with the flat side up as shown in Figure 44 with a maximum of one pipe size reduction.
Page 18 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
Never mount eccentric reducers with the flat side
down. Horizontally mounted concentric reducers
should not be used if there is any possibility of
entrained air in the process fluid. Vertically
mounted concentric reducers are acceptable. In
applications where the fluid is completely
deaerated and free of any vapor or suspended
solids, concentric reducers are preferable to
eccentric reducers
FIGURE 4-3 and FIGURE 4-4
To determine the NPSH available in your system
refer to Figure 4-1 and the following equation.
Avaliable
NPSH =
? Z +
(P-P V)2.31
Sp. Gr.
Hf -He
Where Z = Static head in feet
P = Pressure on surface of liquid in psia
PV = Vapor pressure of liquid at pumping
temperature in psia
Hf = Suction line friction losses in feet
He = Entrance Loss from tank to pipe in feet
For boiling liquids P equals PV and this
item can be omitted from the equation.
If the available NPSH is not equal to or greater than
that required by the pump, it must be increased.
This is usually done by increasing the static head,
Z.
4.7.4 Discharge piping
Install a valve in the discharge line. This valve is
required for regulating flow and/or to isolate the
pump for inspection and maintenance.
Avoid the use of throttling valves and strainers in
the suction line. Start up strainers must be
removed shortly before start up. When the pump is
installed below the source of supply, a valve should
be installed in the suction line to isolate the pump
and permit pump inspection and maintenance.
Never place a valve directly on the suction nozzle
of the pump.
Refer to the Centrifugal Pump Section of the
Hydraulic Institute Standards for additional
recommendations on suction piping.
Refer to section 3.4 for performance and operating
limits.
4.7.3 Net positive suction head
The NPSH required varies with every size of pump
and for any given pump is varies with the capacity.
The NPSH required by your unit can be obtained
from the performance curves available from your
Flowserve Pump Division representative.
When fluid velocity in the pipe is
high, for example, 3 m/s (10 ft/sec) or higher, a
rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping.
4.7.5 Pump and shaft alignment check
After connecting the piping, rotate the pump drive
shaft clockwise (view from motor end) by hand
several complete revolutions to be sure there is no
binding and that all parts are free. Recheck shaft
alignment (see section 4.6). If piping caused unit to
be out of alignment, correct piping to relieve strain
on the pump.
4.7.6 Mechanical seal
It is Flowserve’s standard practice to install the
mechanical seal in the pump prior to shipment.
Specific order requirements may specify that the
seal be shipped separately, or none be supplied. It
is the pump installer’s responsibility to determine if
a seal was installed. If a seal was supplied but not
installed, the seal and installation instructions will
be shipped with the pump.
Page 19 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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Failure to ensure that a seal is
installed may result in serious leakage of the
pumped fluid.
e)
Seal and any seal support system (if used) must be
installed and operated as specified by the seal
manufacturer.
The cover may have ports that have been
temporarily plugged at the factory to keep out
foreign matter. It is the installer’s responsibility to
determine if these plugs should be removed and
external piping connected.
4.8 Electrical connections
4.8.1
Electrical connections must be
made by a qualified Electrician in accordance with
relevant local national and international regulations.
f)
4.8.2
The motor must be wired up in
accordance with the motor manufacturer's
instructions (normally supplied within the terminal
box) including any temperature, earth leakage,
current and other protective devices as appropriate.
The identification nameplate should be checked to
ensure the power supply is appropriate.
4.8.3
See section 5.2, Direction of
rotation before connecting the motor to the
electrical supply.
4.9 Final shaft alignment check for
horizontal pumps
a)
b)
c)
d)
Level baseplate if appropriate.
Mount and level pump if appropriate. Level
the pump by putting a level on the discharge
flange. If not level, adjust the pump bracket
bearing frame as follows:
Check initial alignment. If pump and driver
have been remounted or the specifications
given below are not met, perform an initial
alignment as described in Section 4.6. This
ensures there will be sufficient clearance
between the motor hold down bolts and motor
foot holes to move the motor into final
alignment. The pump and driver should be
within 0.38 mm (0.015 in.) FIM (Full Indicator
Movement) parallel, and 0.0025 mm/mm
(0.0025 in./in.) FIM angular.
Run piping to the suction and discharge to the
pump. There should be no piping loads
transmitted to the pump after connection is
Page 20 of 36
made. Recheck the alignment to verify that
there are no significant changes.
Perform final alignment. Check for soft-foot
under the driver. An indicator placed on the
coupling, reading in the vertical direction,
should not indicate more than 0.05 mm (0.002
in.) movement when any driver fastener is
loosened. Align the driver first in the vertical
direction by shimming underneath its feet.
When satisfactory alignment is obtained the
number of shims in the pack should be
minimized. It is recommended that no more
than five shims be used under any foot. Final
horizontal alignment is made by moving the
driver. Maximum pump reliability is obtained
by having near perfect alignment. Flowserve
recommends no more than 0.05 mm (0.002
in.) parallel, and 0.0005 mm/mm (0.0005
in./in.) angular misalignment (see Section
6.8.7.2).
Operate the pump for at least an hour or until it
reaches final operating temperature. Shut the
pump down and recheck alignment while the
pump is hot. Piping thermal expansion may
change the alignment. Realign pump as
necessary.
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
5 COMMISSIONING, STARTUP,
OPERATION AND SHUTDOWN
5.3 Guarding
Power must never be applied to the driver with the
coupling guard removed.
5.1 Pre-commission procedure
Pre start-up checks
Prior to starting the pump preform the following
checks. All checks are described in the Maintenance
Section of this manual.
?
Pump and motor properly secured to the
baseplate
?
All fasteners tightened to the correct torque
?
Coupling guard in place and not rubbing
?
Rotation check, see section 5.2
This is absolutely essential
?
Shaft seal properly installed (if field installed)
?
Seal support system operational (if used)
?
Pump instrumentation is operational (if used)
?
Pump is primed
?
Pump shaft rotates freely by hand
Preliminary to starting
Read this instruction book thoroughly before starting
the unit. Make sure the following items are checked
before starting:
?
?
?
?
?
Alignment
Lubricate the driver (if required)
Check the direction of rotation of the driver
Lubricate the coupling (if required)
Fill the pump with liquid. If a priming device is
used, turn it on before the pump is started
5.2 Direction of rotation
5.2.1 Rotation check
Check the rotation of the motor before connecting the
shaft coupling. A direction arrow is cast on the
casing. Make sure the motor rotates in the same
direction.
5.4 Priming and auxiliary supplies
The D-800 is a centrifugal pump and is unable to
move liquid unless primed. A pump is said to be
“primed” when the casing and the suction piping are
completely filled with liquid. When a condition exists
where the suction pressure may drop below the
pump’s capability, a low-pressure control device
should be added to shut the pump down when the
pressure drops below a predetermined minimum.
Priming
Before starting any centrifugal pump it is absolutely
necessary that both the casing and suction pipe be
completely filled with liquid. This priming can be
accomplished by any of the following methods.
a) When the liquid supply level is above the center
line of the pump, it is primed by opening the
suction and discharge valves. The inflowing liquid
will displace the air and fill the suction line, pump
casing, and discharge line up to the level of
supply.
b) Where the pump is operating with suction lift and
the suction line is equipped with a foot valve, the
system is filled with liquid by filling through the
discharge piping.
c) When the pumps operating on a suction lift where
foot valves will not operate properly, a priming
chamber may be used.
d) Instead of the preceding methods of filling the
pump, one of a number of types of air removal
apparatus may be used, depending upon the
facilities available. This apparatus is required
when the pump operates under a suction lift and
there is no foot valve in the suction pipe. The
connections are made in the top if the pipe at the
pump suction opening. To prime, shut the
discharge valve and do not start the driver until
the pump and piping are full or water.
5.2.2 Coupling installation
Remove all protective material from the coupling and
shaft. Install the coupling as advised by the coupling
manufacturer. Pumps are normally shipped without
the spacer installed, but with the hubs installed.
Page 21 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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5.5 Starting the pump
5.5.1 Open the suction valve to full open position.
Always leave the suction valve open while the pump
is operating. Any throttling or adjusting of flow must
be done through the discharge valve. Partially
closing the suction valve can create serious NPSH
and pump performance problems.
Operating a pump with both the
suction and discharge valves closed could cause an
explosion.
5.5.2 Ensure the pump is primed. (See section 5.4)
5.5.3 Start the driver (typically, an electric motor).
5.5.4 Slowly open the discharge valve until the
desired flow is reached.
It is important that the discharge valve
be opened within a short interval after starting the
driver. Failure to do this could cause a dangerous
build up of heat, and possibly an explosion.
Starting
The procedure for starting the unit will vary somewhat
with each installation but the following steps will
generally apply:
a) Make certain that suction and discharge valves
are open.
b) Start the driver.
c) Check to see that the pump is delivering liquid.
d) When in service for about one half hour check for
quiet operation and temperature of bearings.
After the pump reaches operating temperature
shut it down. Then check the alignment and
check for binding.
5.6 Running or operation
5.6.1 Minimum continuous flow
Minimum continuous stable flow is the lowest flow at
which the pump can operate. The size of the pump,
the energy absorbed, and the liquid pumped are
some of the considerations in determining the
minimum continuous flow (MCF).
The minimum continuous flow (capacity) is
established as a percentage of the best efficiency
point (BEP).
5.6.2 Minimum thermal flow
Pumps also have a minimum thermal flow. This is
defined as the minimum flow that will not cause an
excessive temperature rise. Minimum thermal flow is
application dependent.
Do not operate the pump below
minimum thermal flow, as this could cause an
excessive temperature rise.
Avoid running a centrifugal pump at drastically
reduced capacities or with discharge valve closed for
extended periods of time. This can cause severe
temperature rise and the liquid in the pump may
reach its boiling point. If this occurs, the mechanical
seal will be exposed to vapor, with no lubrication, and
may score or seize to the stationary parts. Continued
running under these conditions when the suction
valve is also closed can create an explosive condition
due to the confined vapor at high pressure and
temperature.
Thermostats may be used to safeguard against over
heating by shutting down the pump at a
predetermined temperature.
Safeguards should also be taken against possible
operation with a closed discharge valve, such as
installing a bypass back to the suction source. The
size of the bypass line and the required bypass flow
rate is a function of the input horsepower and the
allowable temperature rise.
5.6.3 Reduced head
Note that when discharge head drops, the pump’s
flow rate usually increases rapidly. Check motor for
temperature rise as this may cause overload. If
overloading occurs, throttle the discharge.
5.6.4 Surging condition
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping.
5.6.5 Operation in sub-freezing conditions
When using the pump in sub-freezing conditions
where the pump is periodically idle, the pump should
be properly drained or protected with thermal devices
which will keep the liquid in the pump from freezing.
Page 22 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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5.7 Stopping and shutdown
The procedure for stopping may vary with each
installation the following steps will generally apply
a) Close the discharge valve.
b) Shut down the driver.
c) Close the suction valve.
5.8 Hydraulic, mechanical and electrical
duty
5.8.1 Net positive suction head (NPSH)
Net positive suction head - available (NPSHA) is the
measure of the energy in a liquid above the vapor
pressure. It is used to determine the likelihood that a
fluid will vaporize in the pump. It is critical because a
centrifugal pump is designed to pump a liquid.
Vaporization in a pump will result in damage to the
pump, deterioration of the Total differential head
(TDH) and possibly a stop of pumping.
Net positive suction head - required (NPSHR ) is the
decrease of fluid energy between the inlet of the
pump and the point of lowest pressure in the pump.
The decrease occurs because of friction losses and
fluid accelerations in the inlet region of the pump,
particularly accelerations as fluid enters the impeller
vanes. The value for NPSHR for the specific pump
purchased is given on the pump performance curve.
5.8.2 Specific gravity (SG)
Pump capacity and total head are constant with SG.
However pressure displayed on a pressure gauge is
directly proportional to SG. Power absorbed is also
directly proportional to SG. Therefore, check that any
change in SG will not overload the pump driver or
overpressurize the pump.
5.8.3 Viscosity
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. For a given flow rate the power absorbed
increases with the increased viscosity, and reduces
with reduced viscosity.
5.8.4 Pump speed
Changing the pump speed affects flow, total head,
power absorbed, NPSHr, noise and vibration levels.
Flow varies in direct proportion to pump speed. Head
varies as speed ratio squared. Power varies as
speed ratio cubed. If increasing speed ensure the
maximum working pressure is not exceeded, driver is
not overloaded, NPSHa>NPSHr, noise and vibration
are within local requirements and regulations.
For a pump to operate properly the NPSHA must be
greater than the NPSHR . Good practice dictates that
this margin should be at least 1.5 m (5 ft) or 20%,
whichever is greater.
Ensuring that NPSHA is larger than
NPSHR by the suggested margin will enhance pump
performance and reliability. It will also reduce the risk
of cavitation, which can severely damage the pump.
Page 23 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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6 MAINTENANCE
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work
is carried out by authorized and qualified personnel
who have adequately familiarized themselves with
the subject matter by studying this manual in detail.
(See also section 1.6.2.)
Any work on the machine must be performed when it
is at a standstill. It is imperative that the procedure
for shutting down the machine is followed, as
described in section 5.7.
On completion of work all guards and safety devices
must be re-installed and made operative again.
Before restarting the machine, the relevant
instructions listed in section 5, Commissioning, start
up, operation and shut down must be observed.
Oil and grease leaks may make the ground
slippery. Machine maintenance must always
begin and finish by cleaning the ground and the
exterior of the machine.
Never clean equipment with flammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
Refer to the parts list shown in section 8 for item
number references used throughout this section.
6.1 Maintenance schedule
It is recommended that a maintenance plan and
schedule be implemented, in accordance with these
User Instructions, to include the following:
a) Any auxiliary systems installed must be
monitored, if necessary, to ensure they function
correctly.
b) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
c) Check that the duty condition is in the safe
operating range for the pump.
d) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
e) Check dirt and dust is removed from areas around
close clearances, bearing housings and motors.
Check coupling alignment and re-align if necessary
If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.
When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.
Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean
clothes.
Before working on the pump, take measures to
prevent the pump from being accidentally started.
Place a warning sign on the starting device:
"Machine under repair: do not start".
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning sign on
the fuse box or main switch:
"Machine under repair: do not connect".
6.1.1 Preventive maintenance
The following sections of this manual give instructions
on how to perform a complete maintenance overhaul.
However, it is also important to periodically repeat the
Pre start-up checks listed in section 5.1. These
checks will help extend pump life as well as the
length of time between major overhauls.
6.1.2 Need for maintenance records
A procedure for keeping accurate maintenance
records is a critical part of any program to improve
pump reliability. There are many variables that can
contribute to pump failures. Often long term and
repetitive problems can only be solved by analyzing
these variables through pump maintenance records.
6.1.3 Cleanliness
One of the major causes of pump failure is the
presence of contaminants in the bearing housing.
This contamination can be in the form of moisture,
dust, dirt and other solid particles such as metal
chips. Contamination can also be harmful to the
mechanical seal (especially the seal faces) as well as
other parts of the pump.
Page 24 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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6.1.4 Mechanical seal
A pump equipped with a mechanical seal must not be
run until the pump casing is full of liquid. Running a
pump dry will damage the mechanical seal.
For further information on assembly of the
mechanical seal refer to the following subsections.
6.1.5 Bearing lubrication
Motors may have grease lubricated bearings which
may require periodic replacement of grease. Refer to
the instructions on/or supplied with motor.
The D-814 pump bearing frame is equipped with
sealed for life bearings which do not require
additional lubrication.
6.2 Spare parts
The decision on what spare parts to stock varies
greatly depending on many factors such as the
criticality of the application, the time required to buy
and receive new spares, the erosive/corrosive nature
of the application, and the cost of the spare part.
Section 8 identifies all of the components that make
up each pump addressed in this manual.
6.2.1 Order of spare parts
Flowserve keeps records of all pumps that have been
supplied. Spare parts can be ordered from your local
Flowserve Distributor or Representative. When
ordering spare parts the following information should
be supplied:
Model D-814 or D-824
a) Serial number
b) Size type
c) Part name – see section 8
d) Part item number – see section 8
e) Material of construction (if known)
f) Number of parts required
g) Impeller diameter
The pump size and serial number can be found on
the name plate. See section 3.2.
6.2.2 Returning parts
All materials returned to the factory must have a
Return Material Authorization. Consult the nearest
Flowserve Pump Division representative for shipping
instructions and a Return Material Order Number.
Unnecessary delays are avoided when parts or
equipment are returned to the factory using the
correct procedure.
a) Contact your nearest Flowserve Pump Division
represtative, listing the material to be returned
and the reasons for returning it. Make sure you
give the description of the part and it’s item
number from section 8.
b) On receipt of the Return Material Order Number,
mark or tag the material to be returned with this
order number. In cases where more than one
part or box is returned, print or stencil your name
and the Return Material Order Number on each
part or box. This will facilitate quick identification.
c) Articles being returned should be carefully
packed to prevent damage from handeling or
from the exposure to weather. Give the method
and date of shipment. This will notify the factory
that the material is enroute.
6.3 Recommended spares and
consumable items
Mechanical seal, bearings, shaft, impeller, and
gaskets. See section 8 for part lists and drawings.
6.4 Fastener torques
Item Description
2913
Impeller
screw
Frame
Frame 15 in.
size 143- size 254 Pumps
215
and up
.
15 lbf ft
.
20 lbf ft
.
30 lbf ft
Item Description 4, 5, 6 in. 8-13 in. 15 in.
Pumps Pumps Pumps
6820 Casing bolts
Page 25 of 36
.
15 lbf ft
.
30 lbf ft
.
60 lbf ft
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
6.5 Disassembly procedure
6.6 Examination and repair of parts
a) Remove bolts which hold casing to cover.
b) Separate casing from cover (a pry bar or large
screw driver can be used if needed).
c) Remove old casing gasket.
d) Remove the impeller fastening hardware.
e) Remove the impeller and key from the shaft.
f) The sleeve and mechanical seal rotating
assembly can be removed from the shaft as a
unit.
g) Remove the bolts which hold the cover to the
motor or frame.
h) Remove the cover from the motor or frame.
i) Working from the backside of the cover, push the
seal seat out using a plastic drift or other suitable
device.
j) Remove the rotating assembly portion of the
mechanical seal assembly from the sleeve.
k) Casing wear ring, if equipped, can be removed
through the suction opening by the same method
as for the cover ring, using a specially sharpened
drift pin or by drilling holes in the ring to split it.
Do not strike the shaft, impeller or
sleeve with a hammer. This will damage the ball
bearings and shaft.
6.5.1 Disassembly of frame
a) If there is any reason to suspect a bent shaft or a
misalignment problem, the shaft should be
checked for runout with a dial indicator before
disassembling the bearing frame. Maximum
runout at mechanical seal is 0.002 in.
b) To disassemble the bearing frame, remove the 4
cap screws that hold the bearing cover [3260] to
the bearing housing [3200].
c) Remove the shaft [2100] and bearings [3041 and
3043] by pressing on the impeller end of the
shaft. Protect the threaded end of the shaft
during this operation. In this process the deflector
[2540] will be pushed off the shaft.
d) The bearings may be removed from the shaft by
conventional pressing or pulling methods once
the retaining ring [2530] is removed.
With pump liquid end dissembled, clean all parts and
check for worn and damaged areas. It is seldom
economical on the D-800 pumps to repair damaged
or worn parts. Therefore, when a part is unusable, it
should be replaced.
6.6.1 Casing
Clean and inspect gasket surfaces for damaged
areas that would cause leaks. Check casing wear
ring surfaces for excessive wear. Figure 6-2 gives
standard casing wear ring clearances for cover and
casing sides of the impeller.
6.6.2 Impeller
Check casing wear ring surfaces for excess wear,
impeller vanes, and gasket surfaces of impeller hub
for damage. If excessively worn or eroded, the
impeller must be replaced.
6.6.2.1 Impeller balancing
Shaft whip is deflection where the centerline of the
impeller is moving around the true axis of the pump.
It is not caused by hydraulic force but rather by an
imbalance with the rotating element. Shaft whip is
very hard on the mechanical seal because the faces
must flex with each revolution in order to maintain
contact. To minimize shaft whip it is imperative that
the impeller is balanced. All impellers manufactured
by Flowserve are balanced after they are trimmed. If
for any reason, a customer trims an impeller, it must
be re-balanced.
Pipe Strain Movement
6.6.3 Alignment
Misalignment of the pump and motor shafts can
cause the following problems:
? Failure of the mechanical seal
? Failure of the motor and/or pump bearings
? Failure of the coupling
? Excessive vibration/noise
Page 26 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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The schematics below show the technique for a
typical rim and face alignment using a dial indicator.
It is important that this alignment be done after the
flanges are loaded, and at typical operating
temperatures.
Alignment
6.6.7 Motor shaft
Check the shaft for any bent condition by installing
the sleeve, clamping a dial indicator to the motor
frame face and reading a runout at the center of the
sleeve while turning the shaft by hand. Maximum
allowable runout is 0.002 inches for proper
performance of mechanical seal. A runout reading
greater than this maximum indicates the motor
requires repairs beyond the scope of this instruction
book.
6.7 Assembly of pump and seal
The D-814 and D-824 pumps are easy to put
together. Tasks requiring the most care are the
installation of the mechanical seal and bearings.
Many companies today are using laser alignment
which is a more sophisticated and accurate
technique. With this method a laser and sensor
measure misalignment. This is fed to a graphic
display that shows the required adjustment for each
of the motor feet.
6.6.3.2 Vibration analysis
Vibration analysis is a type of condition monitoring
where a pump’s vibration “signature” is monitored on
a regular, periodic basis. A problem can be noticed
before it becomes serious by using this tool. This can
also help find the root cause of the problem and
possible solutions.
On a centrifugal pump causes can include the
following: unbalance, misalignment, defective
bearings, resonance, hydraulic forces, cavitation and
recirculation.
Flowserve urges customers to work with an
equipment supplier or consultant to establish an ongoing vibration analysis program.
6.6.4 Cover
Clean and inspect gasket surfaces. Clean the
mechanical seal cavity. Check cover ring for wear
and excess clearance. See Figure 6-2. Cover rings
may be driven out by use of a hammer and drift pin.
Removing cast iron casing rings requires special
procedures beyond the scope of this instruction book.
6.6.5 Sleeve
Check for any damage to gasket surface on impeller
end, O-ring groove on driver end, or outside diameter
where rubber bellows of mechanical seal contacts.
6.6.6 Mechanical seal
It is normal pratice to replace the mechanical seeal
when rebuilding a pump.
a) Study section 8, Parts List and Drawings, and
become familiar with the name of each part of the
assembled pump.
b) Make sure all the parts are clean and ready for
assembly. This means no dirt or pieces of old
gaskets in the joints between the motor, cover
and casing. Make sure the parts around the
mechanical seal are clean. Dirt and misalignment
will ruin the mechanical seal.
c) Install the sleeve O-ring in place against the shaft
shoulder. Sharp edges of the keyway can cut the
O-ring.
d) Press in the cover ring, beveled edge first, using
a pressure tool that will hold the ring square with
the cover bore. A little lubricant will ease
pressing. Be careful not to gouge or distort the
ring.
e) Push the stationary element squarely into the
cover. The stationary element O-ring can be
lubricated to ease installation into the cover.
Don’t install the cover on the motor or bearing
frame yet. Clean the face of the stationary
element.
f) Check the sleeve fit on the motor shaft. It should
slide easily into place. If it doesn’t, find out why.
Do not try to drive the sleeve on to the shaft with
a hammer. Check to make sure there are no
score marks or scratches on the sleeve.
g) Install the cover and tighten the bolts that hold it
to the motor or bearing frame. Make sure the
nameplate is properly positioned.
h) Slide the sleeve on the shaft so that it covers the
sleeve O-ring and butts against the shoulder.
i) Lubricate the inside of the rotating element
bellows and install on the sleeve by hand. A
twisting motion may be needed to make it ride
smoothly over the shoulders on the sleeve. Push
it by hand until it contacts the stationary element.
Install the spring and spring holder.
Page 27 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
Install the retaining ring using one hand to hold
the retaining ring pliers and the other hand to
compress the spring. When the spring pressure
is released, the spring will push the sleeve
outward, temporarily exposing the sleeve O-ring.
Install the key, first twisting the sleeve on the
shaft untill both keyways line up.
Install the sleeve gasket.
Place the impeller on the shaft, engaging the key.
Put the impeller screw gasket, impeller washer
and impeller washer gasket together on the
impeller screw as a subassembly.
Install the impeller screw subassembly. With one
hand, push the impeller back against the
mechanical seal spring and with the other hand
turn the impeller screw in hand tight.
.
Tighten the impeller screw 15 lbf ft torque for 3/8
.
in. thread (motor frame sizes 143-215), 20 lbf ft
torque for 1/2 in. thread (frame 254 up), and 30
.
lbf ft torque for 5/8 in. thread (15 in. pumps).
Install the casing gasket in the casing.
Install the casing and tighten all bolts. Tighten the
.
bolts 15 lbf ft torque on 4, 5 and 6 in. pumps, 30
.
lbf ft torque on 8, 9, 10, 11, 12 and 13 in. pumps
.
and 60 lbf ft torque on 15 in. pumps.
Turn the motor shaft and check for and binding
or rubs caused by such things as damaged or
misaligned parts. Any such conditions must be
corrected before the pump is run.
The pump is now ready for installation.
6.7.1 Assembly of frame
Use the following procedure to assemble the bearing
frame.
a) Press bearings on shaft. Note that the inboard
bearing [4041] can face either way. However, the
outboard bearing [4043] must face in the proper
direction, as illustrated in section 8.5.
b) Install the shaft and bearing subassembly in the
bearing housing [3200] by inserting from coupling
end and pushing through until the retaining ring
contacts the back face of the housing.
c) Install bearing cover [3260] and bolts.
d) Install deflector [2540].
e) Install the pump bracket on the frame using its
hardware.
Page 28 of 36
Figure 6-2
Pump Size
1 1/2x1x6T
2x1x8T
2x1x6T
2 1/2x1 1/2x9F
3x2x9F
4x3x9F
5x4x12F
6x5x12F
5x4x15F
6x5x15F
2x1x10F
3x1 1/2x10F
2 1/2x1 1/2x8T
2 1/2x1 1/2x6T
2 1/2x1 1/2x5T
3x2x10F
3x2x8T
3x2x6T
3x2x5F
3x2x5T
2 1/2x2 1/2x4T
3x3x4F
1 1/2x1x6F
1 1/2x1x8F
3x1 1/2x5F
3x1 1/2x6F
3x1 1/2x8F
3x2x8F
3x2x6F
4x3x10F
4x3x8F
4x3x6F
4x3x5F
6x4x8F
6x4x6F
6x4x10F
6x4x11F
3x1 1/2x13F
3x2x13F
4x3x13F
6x4x13F
Casing Ring
Diameter
Clearances
Inches
0.01-0.015
0.010-0.015
0.010-0.015
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.018-0.022
0.018-0.024
0.018-0.024
0.018-0.024
0.018-0.024
0.018-0.024
0.018-0.024
0.018-0.024
0.021-0.027
0.021-0.027
0.021-0.027
0.021-0.027
0.021-0.027
0.021-0.027
0.021-0.027
0.021-0.027
0.018-0.024
0.018-0.024
0.021-0.027
0.028-0.034
Cover Ring
Diameter
Clearances
Inches
0.010-0.015
0.010-0.015
0.010-0.015
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.010-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.010-0.015
0.010-0.015
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.012-0.017
0.021-0.027
0.021-0.027
0.021-0.027
0.012-0.017
0.021-0.027
0.021-0.027
0.021-0.027
0.021-0.027
0.018-0.024
0.018-0.024
0.021-0.027
0.028-0.032
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
7 FAULTS; CAUSES AND REMEDIES
Troubleshooting
The following is a guide to troubleshooting problems with Flowserve D-800 pumps. Common problems are
analyzed and solutions offered. Obviously, it is impossible to cover every possible scenario. If a problem exists
that is not covered by one of the examples, then refer to one of the books listed in the Sources of additional
information section or contact a Flowserve Sales Engineer or Distributor/Representative for assistance.
FAULT SYMPTOM
Pump not reaching design flow rate
?
Pump not reaching design head (TDH)
?
No discharge or flow with pump running
?
Pump operates for short period, then loses prime
?
Excessive noise from wet end
?
Excessive noise from power end
?
?
?
?
?
? ?
? ?
POSSIBLE REMEDIES
Insufficient NPSH. (Noise may not be
present.)
System head greater than anticipated.
? ? ?
? ?
PROBABLE CAUSES
Entrained air. Air leak from atmosphere on
suction side.
?
Recalculate NPSH available. It must be greater than the
NPSH required by pump at desired flow. If not, redesign
suction piping, holding number of elbows and number of
planes to a minimum to avoid adverse flow rotation as it
approaches the impeller.
Reduce system head by increasing pipe size and/or
reducing number of fittings. Increase impeller diameter.
(NOTE: Increasing impeller diameter may require use of
a larger motor.)
1. Check suction line gaskets and threads for tightness.
2. If vortex formation is observed in suction tank, install
vortex breaker.
3. Check for minimum submergence
? ?
Entrained gas from process.
Process generated gases may require larger pumps.
? ?
Speed too low.
Check motor speed against design speed.
? ? ?
Direction of rotation wrong.
? ?
Impeller too small.
? ?
Wet end parts (casing cover, impeller) worn,
corroded or missing.
Not properly primed.
After confirming wrong rotation, reverse any two of three
leads on a three phase motor. The pump should be
disassembled and inspected before it is restarted.
Replace with proper diameter impeller. (NOTE:
Increasing impeller diameter may require use of a larger
motor.)
Replace part or parts.
? ?
?
Impeller rubbing.
Damaged pump shaft, impeller.
? ?
?
Repeat priming operation, recheck instructions. If pump
has run dry, disassemble and inspect the pump before
operation.
1. Check and reset impeller clearance.
2. Check outboard bearing assembly for axial end play.
Replace damaged parts.
Abnormal fluid rotation due to complex suction Redesign suction piping, holding the number of elbows
piping.
and planes to a minimum to avoid adverse fluid rotation
as it approaches the impeller.
Page 29 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
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FAULT SYMPTOM
Pump not reaching design flow rate
?
Pump not reaching design head (TDH)
?
No discharge or flow with pump running
?
Pump operates for short period, then loses prime
?
Excessive noise from wet end
?
Excessive noise from power end
?
?
?
?
?
?
?
?
?
?
?
PROBABLE CAUSES
POSSIBLE REMEDIES
Bearing contamination appearing on the
raceways as scoring, pitting, scratching or
rusting caused by adverse environment and
entrance of abrasive contaminants from
atmosphere.
1. Work with clean tools in clean surroundings.
2. Remove all outside dirt from housing before exposing
bearings.
3. Handle with clean dry hands.
4. Treat a used bearing as carefully as a new one.
5. Use clean solvent and flushing oil.
6. Protect disassembled bearing from dirt and moisture.
7. Keep bearings wrapped in paper or clean cloth while
not in use.
8. Clean inside of housing before replacing bearings.
9. Check oil seals and replace as required.
10. Check all plugs and tapped openings to make sure
that they are tight.
Brinelling of bearing identified by indentation on When mounting the bearing on the drive shaft use a
the ball races, usually caused by incorrectly
proper size ring and apply the pressure against the inner
applied forces in assembling the bearing or by ring only. Be sure when mounting a bearing to apply the
shock loading such as hitting the bearing or
mounting pressure slowly and evenly.
drive shaft with a hammer.
False brinelling of bearing identified again by
1. Correct the source of vibration.
either axial or circumferential indentations
2. Where bearings are oil lubricated and employed in
usually caused by vibration of the balls between units that may be out of service for extended periods,
the races in a stationary bearing.
the drive shaft should be turned over periodically to
relubricate all bearing surfaces at intervals of one to
three months.
Thrust overload on bearing identified by flaking Follow correct mounting procedures for bearings.
ball path on one side of the outer race or in the
case of maximum capacity bearings, may
appear as a spalling of the races in the vicinity
of the loading slot. These thrust failures are
caused by improper mounting of the bearing or
excessive thrust loads.
Misalignment identified by fracture of ball
Handle parts carefully and follow recommended
retainer or a wide ball path on the inner race
mounting procedures. Check all parts for proper fit and
and a narrower cocked ball path on the outer
alignment.
race. Misalignment is caused by poor mounting
practices or defective drive shaft. For example,
bearing not square with the centerline or
possibly a bent shaft due to improper handling.
Bearing damaged by electric arcing identified 1. Where current shunting through the bearing cannot
as electro- etching of both inner and outer ring be corrected, a shunt in the form of a slip ring assembly
as a pitting or cratering. Electrical arcing is
should be incorporated.
caused by a static electrical charge emanating 2. Check all wiring, insulation and rotor windings to be
from belt drives, electrical leakage or short
sure that they are sound and all connections are
circuiting.
properly made.
3. Where pumps are belt driven, consider the
elimination of static charges by proper grounding or
consider belt material that is less generative.
Page 30 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
8 PARTS LIST AND DRAWINGS
8.1 Model D-814 (flanged)
Parts list
Item
1100
6820
2200
2100
2400
3041
3043
2500
6700
3260
2540
Description
Casing
Bolt
Impeller
Shaft
Sleeve
Bearing, Inboard
Bearing, Outboard
Ring
Key
Bearing Cover
Deflector
Item
3120
4240
3134
4220
6569
3200
2530
6580
1500
2905
2913
1220
Page 31 of 36
Description
Pump Bracket
Stationary Element
Support Foot
Rotating Element
Plug
Bearing Housing
Retaining Ring
Nut
Casing Wear Ring (Optional)
Washer
Impeller Screw
Cover
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
8.2 Model D-814 (threaded)
Parts list
Item
1100
6820
2200
2100
2400
3041
3043
2500
6700
3260
2540
Description
Casing
Bolt
Impeller
Shaft
Sleeve
Bearing, Inboard
Bearing, Outboard
Ring
Key
Bearing Cover
Deflector
Item
3120
4240
3134
4220
6569
3200
2530
6580
1500
2905
2913
1220
Page 32 of 36
Description
Pump Bracket
Stationary Element
Support Foot
Rotating Element
Plug
Bearing Housing
Retaining Ring
Nut
Casing Wear Ring (Optional)
Washer
Impeller Screw
Cover
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
8.3 Model D-824 (flanged)
PARTS LIST
Item
1100
2200
1220
2500
2400
1500
Description
Casing
Impeller
Cover
Ring
Sleeve
Casing Wear Ring (Optional)
Item
6700
4240
4220
2530
6820
6569
Page 33 of 36
Description
Key
Stationary Element
Rotating Element
Retaining Ring
Bolt
Plug
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
8.4 Model D-824 (threaded)
PARTS LIST
Item
1100
2200
1220
2500
2400
1500
Description
Casing
Impeller
Cover
Ring
Sleeve
Casing Wear Ring (Optional)
Item
6700
4240
4220
2530
6820
6569
Page 34 of 36
Description
Key
Stationary Element
Rotating Element
Retaining Ring
Bolt
Plug
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
S
8.5 Exploded parts diagram
Page 35 of 36
D-814, D-824 USER INSTRUCTIONS 75373613 – 05/04
®
9 CERTIFICATION
Certificates are provided where applicable. Examples
are certificates of compliance, certified hydrostatic
test reports, certified performance test reports, etc.
Copies of any certificates sent separately to the
Purchaser should be obtained from Purchaser for
retention with these User Instructions.
10 OTHER RELEVANT DOCUMENTATION
AND MANUALS
10.1 Supplementary user instructions
Supplementary instructions such as for a driver,
instrumentation, controller, seals, sealant systems,
etc. are provided as separate documents in their
original format. If further copies of these are required
they should be obtained from the orginal supplier of
these items.
10.2 Change notes
Any changes made to the product after original
manufacture should be agreed to by Flowserve Pump
Division. A record of these changes should be
maintained with these User Instructions.
10.3 Additional sources of information
The following are excellent sources for additional
information.
Pump Handbook
2nd edition, Igor J. Karassik et al, McGraw-Hill, Inc.,
New York, NY, 1986.
Centrifugal Pump Sourcebook
John W. Dufour and William E. Nelson,
McGraw-Hill, Inc., New York, NY, 1993.
Pumping Manual, 9th edition
T.C. Dickenson, Elsevier Advanced Technology,
Kidlington, United Kingdom, 1995.
Page 36 of 36
®
USA and Canada
Flowserve Corporation
Pump Division
Millennium Center
222 Las Colinas Blvd., 15th Floor
Irving, TX 75039-5421 USA
Telephone: 1 972 443 6500
Toll Free: 1 800 728 PUMP (7867)
Fax:
1 972 443 6800
Latin America
Flowserve S.A. de C.V.
Avenida Paseo de la Reforma #30
2nd Floor, Colonia Juarez Centro
Mexico, D.F.Z.C. 06040
Europe, Middle East & Africa
Flowserve Limited
Pump Division
Harley House, 94 Hare Lane
Claygate, Esher, Surrey KT10 0RB
United Kingdom
Telephone: +44 (0)1372 463 700
Fax:
+44 (0)1372 460 190
Asia Pacific
Flowserve Pte Ltd
Pump Division
200 Pandan Loop, #06-03/04
Pantech 21, Singapore 128388
Telephone: +52 5705 5526
Fax:
+52 5705 1125
Telephone: +65 775 3003
Fax:
+65 779 4607
Visit our web site at: www.flowserve.com
Your Flowserve contact:
Your local Flowserve representative:
To find your local Flowserve representative,
please use the Sales Support Locator System
found at www.flowserve.com
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